Brush head assembly and methods of manufacture

ABSTRACT

A method ( 200 ) for manufacturing a brush head ( 10 ) includes: (i) positioning ( 210 ) a first end ( 23 ) of each of a plurality of bristle tufts ( 21 ) into a tuft plate ( 110 ) comprising a plurality of cavities ( 120 ) each configured to receive at least one of the plurality of bristle tufts; (ii) applying ( 220 ) a force, via a profile plate ( 300 ), to a second end ( 25 ) of the plurality of bristle tufts, wherein the profile plate comprises a predetermined shape complementary to a desired profile configuration of the bristle tufts; and (iii) applying ( 230 ) heat to each of the first ends of the plurality of bristle tufts, via a die plate ( 400 ) comprising at least one cavity ( 410 ) configured to receive at least one of the plurality of the first ends, at a temperature sufficient to at least partially melt each of the first ends into the cavity.

FIELD OF THE INVENTION

The present disclosure is directed generally to a brush head assemblywith bristle tufts retained within an elastomeric matrix, as well as tomethods for manufacturing the brush head assembly.

BACKGROUND

Periodontal diseases are thought to be infectious diseases caused bybacteria present in dental plaques. Tooth brushing is a highly effectivemethod to remove dental plaque from the teeth. Power toothbrushes canenhance the removal of dental plaque. Such power toothbrushes have a setof bristles attached to a brush head which is moved by a driver thatcauses the bristles to scrub dental surfaces.

The brush heads of both manual and power toothbrushes comprise bristleswhich are used to clean the teeth, tongue, and cheeks. In sometoothbrushes, the non-anchored end of the bristles are organized into adesired brushing surface shape, and the anchored ends of the bristlesare then fused together to form a head that is then fixed within apolymer such as a flexible thermoplastic elastomer (TPE). In othertoothbrushes, the bristles are organized into bristle tufts containedwithin retention rings. The retention rings serve to secure the bristletufts within the brush head and often have a hollow circular shape withan interior and exterior circular circumference. During manufacture, thebristle tufts are inserted into the hollow interior of the retentionring, and the bristles are then fused together using heat to form a headwhich cannot be pulled out through the retention ring.

Often, however, the fused bristles and/or retention rings are not firmlysecured within the brush head. As a result, the bristles can be orbecome loose within the brush head, and the bristles might not always bepositioned at an angle optimal for brushing. As such, under the dynamicconditions of motion induced by the power toothbrush operation, forexample, the bristle tuft structure can undergo higher stresses underthe dynamic motion, which could lead to separation. Further, the processof organizing the bristles into tufts, heating the ends and then coolingthe brush head material, or allowing it to cool, in order to fix thetufts in place can be time-consuming and expensive.

Accordingly, there is a need in the art for improved brush headassemblies, and methods of their manufacture, that permanently andefficiently retain bristles within the brush head.

SUMMARY OF THE INVENTION

The present disclosure is directed to inventive methods formanufacturing a brush head with secured bristle tufts. Variousembodiments and implementations herein are directed to manufacturingmethods in which bristle tufts are affixed within an elastomeric matrixresulting in a completed brush head. Using the various embodiments andimplementations herein, cost-effective and efficient production of brushheads with secured bristle tufts is substantially improved. Bristletufts are positioned into positioning cavities of a tuft plate, and aforce is applied to one end of each of the bristle tufts via a profileplate on one side of the tuft plate. On the opposite side of the tuftplate, the other ends of the bristle tufts are heated by a die platecomprising shaping cavities. The heated ends at least partially meltinto the respective shaping cavity, thereby adopting the shape of thecavity. The shaped ends of the bristle tufts are then cooled and ejectedfrom the die plate. According to an embodiment, the profile plateapplies pressure to the ends of the bristle tufts until the ends adopt adesired profile configuration.

Generally in one aspect, a method for manufacturing a brush head isprovided. The method includes: (i) positioning a first end of each of aplurality of bristle tufts into a tuft plate, the tuft plate comprisinga plurality of cavities each configured to receive at least one of theplurality of bristle tufts; (ii) applying a force, via a profile plate,to a second end of each of the plurality of bristle tufts, wherein theprofile plate comprises a predetermined shape complementary to a desiredprofile configuration of the bristle tufts; and (iii) applying heat toeach of the first ends of the plurality of bristle tufts, via a dieplate comprising at least one cavity configured to receive at least oneof the plurality of the first ends, at a temperature sufficient to atleast partially melt each of the first ends into the cavity, whereineach first end of the plurality of bristle tufts adopts the shape of thecavity, wherein the force is applied via the profile plate until thesecond ends of the plurality of bristle tufts adopt the desired profileconfiguration.

According to an embodiment, the force is applied via the profile plateuntil one or more of the plurality of bristles achieves a predeterminedlength between the die plate and the profile plate.

According to an embodiment, the at least one cavity of the die platecomprises a channel configured to receive excess melted bristle tuft.

According to an embodiment, the method further includes the step ofcooling the die plate until the shaped first ends of the plurality ofbristle tufts solidify. According to an embodiment, the die plate iscooled via an airjet or liquid cooling.

According to an embodiment, the method further includes the step ofejecting the shaped first ends of the plurality of bristle tufts fromthe die plate. According to an embodiment, the shaped first ends areejected via ejection pins. According to an embodiment, the shaped firstends are ejected via air pressure

According to an embodiment, the method further includes the step ofmolding a thermoplastic elastomer to create an elastomeric matrix thatat least partially encompasses the shaped first ends of the plurality ofbristle tufts.

According to an aspect is a system for manufacturing a brush head. Thesystem includes: (i) a tuft plate comprising a plurality of tuft platecavities each configured to receive a bristle or bristle tuft; (ii) aprofile plate comprising a predetermined shape complementary to adesired final profile configuration of the bristle tufts, wherein theprofile plate is configured to apply a force to a second end of abristle or bristle tuft positioned within the tuft plate; and (iii) adie plate comprising at least one die plate cavity configured to receivea first end of a bristle or bristle tuft positioned within the tuftplate, wherein the die plate is configured to heat to the first ends ofthe bristle or bristle tufts at a temperature sufficient to at leastpartially melt each of the first ends into the cavity.

According to an embodiment, the profile plate is configured to apply theforce until the second ends of the plurality of bristle tufts adopt thedesired profile configuration, and/or until one or more of the pluralityof bristles achieves a predetermined length between the die plate andthe profile plate.

According to an embodiment, of the at least one cavity of the die platecomprises a channel configured to receive excess melted bristle tuft.

According to an embodiment, the die plate is further configured to coolthe melted first ends of the plurality of bristle tufts until the meltedfirst ends solidify.

According to an embodiment, the die plate is further configured to ejectthe melted first ends of the plurality of bristle tufts from the dieplate.

It should be appreciated that all combinations of the foregoing conceptsand additional concepts discussed in greater detail below (provided suchconcepts are not mutually inconsistent) are contemplated as being partof the inventive subject matter disclosed herein. In particular, allcombinations of claimed subject matter appearing at the end of thisdisclosure are contemplated as being part of the inventive subjectmatter disclosed herein.

These and other aspects of the invention will be apparent from andelucidated with reference to the embodiment(s) described hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the sameparts throughout the different views. Also, the drawings are notnecessarily to scale, emphasis instead generally being placed uponillustrating the principles of the invention.

FIG. 1 is a schematic representation of a side view of a brush headassembly, in accordance with an embodiment.

FIG. 2 is a flowchart of a method for manufacturing a brush headassembly with bristle tufts retained within an elastomeric matrix, inaccordance with an embodiment.

FIG. 3 is a schematic representation of a tuft plate, in accordance withan embodiment.

FIG. 4 is a schematic representation of a tuft plate with positionedbristle tufts, in accordance with an embodiment.

FIG. 5 is a schematic representation of a profile plate, tuft plate, anddie plate, in accordance with an embodiment.

FIG. 6 is a schematic representation of a die plate, in accordance withan embodiment.

FIG. 7 is a schematic representation of a profile plate, tuft plate, anddie plate, in accordance with an embodiment.

FIG. 8 is a schematic representation of a profile plate, tuft plate, anddie plate, in accordance with an embodiment.

FIG. 9 is a schematic representation of a profile plate, tuft plate, anddie plate, in accordance with an embodiment.

FIG. 10 is a schematic representation of shaped bristles in a tuft plateand ejected from a die plate, in accordance with an embodiment.

FIG. 11 is a schematic representation of shaped bristles embedded withinan elastomeric matrix, in accordance with an embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS

The present disclosure describes various embodiments of a brush headassembly with bristle tufts retained within an elastomeric matrix, andmethods of their manufacture. More generally, Applicants have recognizedand appreciated that it would be beneficial to provide a brush headformed with bristles permanently embedded in an elastomeric matrix inorder to improve bristle retention. According to an embodiment bristletufts are positioned into a tuft plate, and force is applied to one endof each of the bristle tufts via a profile plate on one side of the tuftplate while the other ends of the bristle tufts are heated by a dieplate comprising shaping cavities. The heated ends at least partiallymelt into the respective shaping cavity, thereby adopting the shape ofthe cavity. The shaped ends of the bristle tufts are then cooled andejected from the die plate. According to an embodiment, the profileplate applies pressure to the ends of the bristle tufts until the endsadopt a desired profile configuration.

The brush heads disclosed and described herein can be used with varioustypes of brushes, and more specifically, with any manual or powertoothbrush device.

Referring to FIG. 1, in one embodiment, a schematic representation of abrush head assembly 10 is provided. The brush head assembly includes aneck 40, which can be coupled to any manual brush shaft, or, morepreferably, to any actuator and drive shaft (not shown) made or suitablefor powered oral care devices now known or to be developed. The brushhead 32 of the brush head assembly includes a plurality of bristle tufts21, each of which comprises a plurality of bristle strands. According toan embodiment, the bristle tufts are composed of nylon, or anothersuitable material, and optionally can be coated with polyurethane,polybutylene terephthalate (PBT), polyolefin, combinations of these, ora similar polymer.

Each bristle tuft 21 has a first end 23 retained within the brush headassembly 10. The first end of the bristle tufts and the portion of theneck that is the brush neck 42 are retained within a flexibleelastomeric matrix 30 to form a head portion 32 of the brush headassembly 10. According to an embodiment, the elastomeric matrix 30 ispreferably made from a flexible thermoplastic elastomer (TPE), and theretention rings are preferably made from thermoplastic polymer such aspolypropylene. The neck 40 and the brush neck 42 are preferably madefrom a material with a higher elastic modulus value than the elastomericmatrix 30. The second end 25 of each bristle tuft 21 is the portion ofthe bristles that are used in operation, such as to clean a user'steeth.

Referring to FIG. 2, in one embodiment, is a method 200 formanufacturing one or more of the various brush head embodiments andimplementations described or otherwise envisioned herein. For example,brush head 32 can comprise a plurality of bristle tufts 21 each having afirst end 23 and a second end 25, where the first end of each bristletuft is retained within a flexible elastomeric matrix 30 of the brushhead assembly 10. According to an embodiment, the first end portions 23of the bristles are shaped to increase engagement with the elastomericmatrix 30, and/or to increase the force needed to remove the bristletuft from the elastomeric matrix. Many other embodiments andconfigurations of the brush head 32 are possible.

At step 210 of the method, the first end 23 of each of the bristle tufts21 is positioned into a tuft plate, which includes one or more cavities.The cavity is, or each of the plurality of cavities are, configured toreceive at least one of the plurality of bristle tufts. The cavity mayreceive a single bristle, a single bristle tuft, a plurality of bristletufts, or all the bristle tufts. Referring to FIG. 3, in one embodiment,is a top view of a tuft plate 110 with a plurality of tuft cavities 120into which a bristle or bristle tuft 21 is inserted. Referring to FIG.4, in one embodiment, is a side perspective view of a tuft plate 110with a plurality of bristles or bristle tufts 21 inserted into the tuftcavities 120.

At step 220 of the method, a force is applied to the second ends 25 ofthe bristle tufts 21 by a profile plate 300. Prior to or simultaneouslywith this step, the first ends 23 of the bristle tufts 21 are alignedwith or into cavities 410 of a die plate 400. Accordingly, in apreferred embodiment, the cavities 120 of the tuft plate 110 and thecavities 410 of the die plate 400 align such that tufts passing throughthe cavities of the tuft plate can align with and enter into thecavities of the die plate.

According to an embodiment, profile plate 300 comprises a predeterminedshape or profile which is complementary to a desired profileconfiguration of the bristle tufts. For example, many toothbrush bristletufts present a contoured profile that is designed to improve brushingefficacy. The profile plate adopts a configuration complementary to thedesired bristle contoured profile such that as the profile plate pushesagainst or is pushed against the second ends 25 of the bristle tufts,the plurality of bristle tufts can adopt the desired contoured profile.The contoured profile may be any desired profile, including curved,straight, multi-layered, and many other profiles.

According to an embodiment, the profile plate 300 may comprise one plateor a plurality of plates, including a plurality of pins configured toapply pressure to individual bristles or bristle tufts. Other methods orsystems for applying a force to the bristles by one or more profileplate embodiments are possible.

Referring to FIG. 5, in one embodiment, is a schematic representation ofa tuft plate 110 positioning a plurality of bristle tufts 21 via thetuft plate cavities 120. On one side of the tuft plate 110 is theprofile plate 300 with a predetermined shape or profile which iscomplementary to a desired profile configuration of the bristle tufts.On the opposite side of the tuft plate is the die plate 400 comprising aplurality of die plate cavities 410 into which the first ends 23 of thebristle tufts 21 are inserted. The die plate cavities 410 can compriseany shape into which the melting first ends of the bristles will adopt.Accordingly, the die plate cavities can be round, square, triangular,rectangular, oval, or any other size or shape. Referring to FIG. 6, inone embodiment, is a die plate 400 comprising a plurality of triangulardie plate cavities 410. The die plate cavities may optionally comprisean additional structure, including but not limited to rings, aroundand/or through which the first ends 23 of the bristle tufts 21 may passor interact. The additional structure and the first ends of the bristletufts may fuse, mechanically interlock, or otherwise adopt anotherdesired configuration as the first ends of the bristles melt indownstream steps of the method.

At step 230 of the method, the die plate 400 applies heat to the firstends 23 of the plurality of bristle tufts 21 at a temperature sufficientto at least partially melt each of the first ends into the respectivecavity with which it is aligned. For example, the die plate can beheated by an external heat source, or can comprise an internal orattached heat source. The heating temperature will depend on thematerial from which the bristles are manufactured, and/or the speed withwhich the first ends should melt, and/or one or more other factors. Asthe first ends 23 of the bristle tufts melt, the bristles in the bristletufts fuse and also adopt the shape of the die plate cavity 410 intowhich the first ends have been inserted. This is further facilitated bythe force exerted on the second ends 25 of the bristle tufts by theprofile plate 300, as this pushes the bristles in a direction toward thedie plate cavities, promoting the melting first ends to adopt the shapeof the die plate cavity.

According to an embodiment, one or more of the die plate cavities 410comprises a channel 420, as shown in FIG. 7, configured to receiveexcess melted bristle tuft. As the profile plate pushes the second ends25 of the bristle tufts and the die plate heats the firsts ends 23, thefirst ends melt and fill the die plate cavity 410. However, if there ismore melted bristle than the cavity is sized to receive, the excessmelted bristle can escape the cavity via the channels 420.

For example, the contoured profile adopted by the second ends of thebristles due to the force of the profile plate may require that somebristles are shorter than others. Thus, the die plate cavities for theshorter bristles will by necessity have to receive more melted bristlethan die plate cavities for longer bristles. Although the die platecavities may be configured to receive an exact amount of melted bristlebased at least in part on the desired profile configuration of thesecond ends, in other embodiments, one or more of the die plate cavities410 can include a channel 420 configured to receive any excess meltedbristle tuft. In this way, a die plate can accommodate a plurality ofdifferent profiles for the second ends of the bristles, as well as aplurality of different bristle tuft lengths for the device.

Referring to FIG. 7, in one embodiment, is a schematic representation ofa profile plate 300 exerting a force on the second ends 25 of thebristle tufts, positioned by the tuft plate 110, as the die plate 400heats the first ends 23 of the bristle tufts. Comparing FIGS. 5 and 7,for example, the bristle tufts are shortening as force and heat areapplied to the opposite ends of the bristle tufts. The die plate 400comprises a plurality of die plate cavities 410 into which the meltedbristle tufts fill, and one or more of the die plate cavities comprise achannel 420 to receive excess melted bristle tuft.

At step 240 of the method, the profile plate 300 applies the force untilthe second ends 25 of the plurality of bristle tufts 21 adopt thedesired profile configuration. The profile plate may also apply forceuntil the bristles adopt a predetermined length between the die plateand the profile plate. Once the desired length and/or profileconfiguration is adopted, the profile plate may stop applying the force,and/or the die plate may stop heating the bristles.

Referring to FIG. 8, in one embodiment, is a schematic representation ofa profile plate 300 exerting a force on the second ends 25 of thebristle tufts 21, positioned by the tuft plate 110, as the die plate 400heats the first ends 23 of the bristle tufts 21. The profile plate 300has exerted a force on the second ends 25 of the bristle tufts 21 untilthe bristle tufts 21 have adopted a predetermined desired length and/orconfiguration.

At step 250 of the method, the die plate 400 is cooled until the meltedfirst ends of the plurality of bristle tufts, positioned within the dieplate cavities 410, solidify. For example, the die plate may be cooledby air jet, liquid cooling, or by any other method. The die plate orfirst ends may be cooled for a predetermined amount of time, or untilthe first ends are determined to be sufficiently solidified. Referringto FIG. 9, in one embodiment, is a schematic representation of theprofile plate 300, tuft plate 110, and die plate 400 in which the dieplate is being actively or passively cooled to allow the melted andshaped first ends to cool and solidify.

At step 260 of the method, the shaped bristle tufts are removed from thedie plate, by ejection or other method. For example, the shaped bristletufts may be removed by pulling on the tuft plate 110. Alternatively oradditionally, the shaped bristle tufts may be removed by exerting aforce on the first ends 23 via ejection pins and/or air pressure.Referring to FIG. 10, in one embodiment, is a schematic representationof a tuft plate 110 with a plurality of bristle tufts in which the firstends 23 have adopted the shape of the die cavities of the die plate 400,and the second ends 25 have adopted the contour or configuration of theprofile plate 300.

At step 270 of the method, an elastomeric material is molded over thebrush neck 42 and the shaped first ends 23 of the bristle tufts to forman elastomeric matrix 30. According to an embodiment, elastomeric matrix30 is preferably made from a flexible thermoplastic elastomer. The brushneck 42 may be positioned in relation to the first ends 23 of thebristle tufts. Brush neck 42 can be properly positioned using a mold,for example, or other positioning mechanism. According to an embodiment,the hard brush neck 42 can be designed to promote fusing of theelastomeric matrix to the brush neck. For example, if the brush neck ismade from materials such as Spandex®, PolyMeg®, or similar copolymers,this would allow fusing of the elastomer matrix to the brush neck,thereby increasing retention forces. In addition, this design providesadditional flexibility to the bristle tuft within the brush neck, andtherefore additional degrees of freedom of motion within the brush head.However, many other materials and configurations for the brush neck 42are possible.

Referring to FIG. 11, in one embodiment, is a schematic representationof a portion of a brush 10 with a plurality of bristle tufts each havinga first end 23 which has adopted a melted shape, and a second end 25which has adopted a desired profile configuration. The shaped first endsof the bristles have been embedded by an elastomeric matrix 30 formedaround the first ends and the brush neck 42. The shaped ends of thebristles increase retention of bristle tufts in the finished brush headafter the elastomeric matrix is molded around the components.

According to an embodiment, the methods described or otherwiseenvisioned herein enable the first ends of the bristle tufts to adoptany design according to the design of the die plate cavities. The meltedshaped first ends of the bristle tufts can be visible if a portionextends out of the elastomeric matrix. The methods described orotherwise envisioned herein also enable the first ends of the bristletufts to be embedded in the elastomeric matrix or other retainingmechanism without rings or other additional structure. The methodsdescribed or otherwise envisioned herein also enable the second ends ofthe bristle tufts to adopt any design according to the design of theprofile plate.

All definitions, as defined and used herein, should be understood tocontrol over dictionary definitions, definitions in documentsincorporated by reference, and/or ordinary meanings of the definedterms.

The indefinite articles “a” and “an,” as used herein in thespecification and in the claims, unless clearly indicated to thecontrary, should be understood to mean “at least one.”

The phrase “and/or,” as used herein in the specification and in theclaims, should be understood to mean “either or both” of the elements soconjoined, i.e., elements that are conjunctively present in some casesand disjunctively present in other cases. Multiple elements listed with“and/or” should be construed in the same fashion, i.e., “one or more” ofthe elements so conjoined. Other elements may optionally be presentother than the elements specifically identified by the “and/or” clause,whether related or unrelated to those elements specifically identified.

As used herein in the specification and in the claims, “or” should beunderstood to have the same meaning as “and/or” as defined above. Forexample, when separating items in a list, “or” or “and/or” shall beinterpreted as being inclusive, i.e., the inclusion of at least one, butalso including more than one, of a number or list of elements, and,optionally, additional unlisted items. Only terms clearly indicated tothe contrary, such as “only one of” or “exactly one of,” or, when usedin the claims, “consisting of,” will refer to the inclusion of exactlyone element of a number or list of elements. In general, the term “or”as used herein shall only be interpreted as indicating exclusivealternatives (i.e. “one or the other but not both”) when preceded byterms of exclusivity, such as “either,” “one of” “only one of,” or“exactly one of.”

As used herein in the specification and in the claims, the phrase “atleast one,” in reference to a list of one or more elements, should beunderstood to mean at least one element selected from any one or more ofthe elements in the list of elements, but not necessarily including atleast one of each and every element specifically listed within the listof elements and not excluding any combinations of elements in the listof elements. This definition also allows that elements may optionally bepresent other than the elements specifically identified within the listof elements to which the phrase “at least one” refers, whether relatedor unrelated to those elements specifically identified.

It should also be understood that, unless clearly indicated to thecontrary, in any methods claimed herein that include more than one stepor act, the order of the steps or acts of the method is not necessarilylimited to the order in which the steps or acts of the method arerecited.

In the claims, as well as in the specification above, all transitionalphrases such as “comprising,” “including,” “carrying,” “having,”“containing,” “involving,” “holding,” “composed of,” and the like are tobe understood to be open-ended, i.e., to mean including but not limitedto. Only the transitional phrases “consisting of” and “consistingessentially of” shall be closed or semi-closed transitional phrases,respectively.

While several inventive embodiments have been described and illustratedherein, those of ordinary skill in the art will readily envision avariety of other means and/or structures for performing the functionand/or obtaining the results and/or one or more of the advantagesdescribed herein, and each of such variations and/or modifications isdeemed to be within the scope of the inventive embodiments describedherein. More generally, those skilled in the art will readily appreciatethat all parameters, dimensions, materials, and configurations describedherein are meant to be exemplary and that the actual parameters,dimensions, materials, and/or configurations will depend upon thespecific application or applications for which the inventive teachingsis/are used. Those skilled in the art will recognize, or be able toascertain using no more than routine experimentation, many equivalentsto the specific inventive embodiments described herein. It is,therefore, to be understood that the foregoing embodiments are presentedby way of example only and that, within the scope of the appended claimsand equivalents thereto, inventive embodiments may be practicedotherwise than as specifically described and claimed. Inventiveembodiments of the present disclosure are directed to each individualfeature, system, article, material, kit, and/or method described herein.In addition, any combination of two or more such features, systems,articles, materials, kits, and/or methods, if such features, systems,articles, materials, kits, and/or methods are not mutually inconsistent,is included within the inventive scope of the present disclosure.

1. A method for manufacturing a brush head, the method comprising thesteps of: positioning a first end of each of a plurality of bristletufts into a tuft plate, the tuft plate comprising a plurality ofcavities each configured to receive at least one of the plurality ofbristle tufts; applying a force, via a profile plate, to a second end ofeach of the plurality of bristle tufts, wherein the profile platecomprises a predetermined shape complementary to a desired profileconfiguration of the bristle tufts; and applying heat to each of thefirst ends of the plurality of bristle tufts, via a die plate comprisingat least one cavity configured to receive at least one of the pluralityof the first ends of the bristle tufts, at a temperature sufficient toat least partially melt each of the first ends into the cavity, whereineach first end of the plurality of bristle tufts adopts the shape of thecavity.
 2. The method of claim 1, wherein the force is applied via theprofile plate until one or more of the plurality of bristles achieves apredetermined length between the die plate and the profile plate to formthe desired profile configuration.
 3. The method of claim 1, wherein theat least one cavity of the die plate comprises a channel configured toreceive excess melted bristle tuft.
 4. The method of claim 1, furthercomprising the step of cooling the die plate until the shaped first endsof the plurality of bristle tufts solidify.
 5. The method of claim 1,further comprising the step of removing the shaped first ends of theplurality of bristle tufts from the die plate.
 6. The method of claim 5,wherein the shaped first ends are removed via ejection pins.
 7. Themethod of claim 5, wherein the shaped first ends are removed via airpressure.
 8. The method of claim 1, further comprising the step ofmolding a thermoplastic elastomer around the first ends of the bristletufts to create an elastomeric matrix (30) that at least partiallyencompasses the shaped first ends of the plurality of bristle tufts. 9.A system for manufacturing a brush head, the system comprising: a tuftplate comprising a plurality of tuft plate cavities each configured toreceive a bristle or bristle tuft; a profile plate comprising apredetermined shape complementary to a desired final profileconfiguration of the bristle tufts, wherein the profile plate isconfigured to apply a force to a second end of a bristle or bristle tuftpositioned within the tuft plate; and a die plate comprising at leastone die plate cavity configured to receive a first end of a bristle orbristle tuft positioned within the tuft plate, wherein the die plate isconfigured to heat to the first ends of the bristle or bristle tufts ata temperature sufficient to at least partially melt each of the firstends into the cavity.
 10. The system of claim 9, wherein the at leastone cavity of the die plate comprises a channel configured to receiveexcess melted bristle tuft.
 11. The system of claim 9, wherein the dieplate is further configured to cool the melted first ends of theplurality of bristle tufts until the melted first ends solidify.
 12. Thesystem of claim 11, wherein the die plate is further configured toremove the solidified first ends of the plurality of bristle tufts fromthe die plate.
 13. The system of claim 12, wherein the die plate isconfigured to eject the melted first ends of the plurality of bristletufts from the die plate via ejection pins and/or air pressure.